Expandable Stretch Sock

ABSTRACT

A sock having a foot bed configured to expand at least two sizes on the National Association of Hosiery Manufacturers (NAHM) sock size measuring system while comfortably accommodating the foot of the wearer. The body portion and foot bed are mesh knit substantially entirely on the same needle cylinder using heavier body yarns, lighter denier nylon fibers and/or stronger spandex fibers than is typical for manufacturing socks.

BACKGROUND

The disclosure relates generally to socks, and in particular, to a sock having a foot bed that expands to accommodate a multiple-size foot range and shape by incorporating a combination of fiber and knitting techniques.

Socks ordinarily are constructed in a number of size ranges in order to comfortably accommodate feet of different sizes and/or shapes. Provision of socks in such various size ranges potentially increases production costs due to the need to produce (and vendors to inventory) socks in multiple sizes.

Accordingly, providing comfortable socks capable of accommodating a variety of foot sizes and/or shapes.

SUMMARY

Generally, example implementations of the present disclosure may include a sock having a foot bed that expands to accommodate multiple foot shape and size ranges by a combination of preselected fiber and/or knitting techniques.

More specifically, example implementations of the present disclosure include a sock to be worn on the foot of a wearer, comprising a body portion including a foot bed configured to expand at least two sizes on the National Association of Hosiery Manufacturers (NAHM) sock size measuring system while comfortably accommodating the foot of the wearer.

Example implementations of the present disclosure include a sock having a foot bed configured to expand at least two sizes on the NAHM sock size measuring system while comfortably accommodating the foot of the wearer. The body portion and foot bed may be mesh knit substantially entirely on the same needle cylinder using heavier body yarns, lighter denier nylon fibers and/or stronger spandex fibers than is typical for manufacturing socks.

Example implementations of the present disclosure also include a method providing a sock knitted substantially entirely on the same needle group/cylinder in order to achieve multiple sizing capability for the resulting sock. Through use of heavier weight body yarns, lighter denier nylon and/or stronger spandex fibers to control the sizing, combined with a mesh knitting technique, the resultant sock achieves a foot bed that gives a broader range of fit for both foot length and width.

Further example implementations of the present disclosure can include the sock being manufactured to accommodate at least one of a group consisting of: shoe sizes 10-13, sock sizes 7-9, and NAHM sizes 7-9; shoe sizes 4-10, sock sizes 5-7, and NAHM sizes 5-7; and shoe sizes 000-4, sock sizes 3-5, and NAHM sizes 3-5.

Example implementations of the present disclosure can include the body portion and foot bed being knit substantially entirely mesh knit and/or knit on the same needle cylinder.

Example implementations of the present disclosure can include a method for manufacturing a sock to be worn on the foot of a wearer, comprising selecting all or at least one of a group consisting of: body yarns of heavier weight than is typical for manufacturing socks; fibers of lighter denier nylon fibers than is typical for manufacturing socks; and stronger spandex fibers than is typical for manufacturing socks; and mesh knitting a body portion and a foot bed to produce the sock, wherein the body portion and foot bed are configured to expand at least two sizes on the NAHM sock size measuring system while comfortably accommodating the foot of the wearer. Methods can also include the mesh knitting of the body portion and foot bed being substantially entirely performed on the same needle cylinder.

Example implementations of the present disclosure can include a sock to be worn on or about the foot of a wearer, including a body portion including a foot bed configured to expand at least two sizes on the NAHM sock size measuring system while comfortably accommodating the foot of the wearer, wherein the body portion and foot bed are knit substantially entirely on the same needle cylinder and wherein the body portion and foot bed are knit substantially using all, or at least one, of a group consisting of: body yarns of heavier weight than is typical for manufacturing socks; fibers of lighter denier nylon fibers than is typical for manufacturing socks; and stronger spandex fibers than is typical for manufacturing socks. The resulting sock then accommodates at least one of a group consisting of: shoe sizes 10-13, sock sizes 7-9, and NAHM sizes 7-9; shoe sizes 4-10, sock sizes 5-7, and NAHM sizes 5-7; and shoe sizes 000-4, sock sizes 3-5, and NAHM sizes 3-5.

Accordingly, in view of the foregoing, implementations of the present disclosure provide socks of improved comfort for the wearer and/or capable of accommodating a variety of foot sizes and shapes. In particular, a sock of the present disclosure is configured to expand up to two sizes on the NAHM sock size measuring system, thereby allowing such sock to accommodate multiple foot shapes and sizes while still allowing for a comfortable fit capable of providing the consumer with a customized feel. More specifically, in certain non-limiting examples, socks in accordance with the disclosure herein accommodated multiple size ranges, such as: in one example embodiment, a sock accommodates wearers of shoe sizes 10-13, sock sizes 7-9, and NAHM sizes 7-9; in a second example embodiment, a sock accommodates wearers of shoe sizes 4-10, sock sizes 5-7, and NAHM sizes 5-7; and in a third example embodiment, a sock accommodates wearers of shoe sizes 000-4, sock sizes 3-5, and NAHM sizes 3-5.

Furthermore, the abovementioned implementations of the present disclosure, and the features and applications thereof, are not to be understood as being limited to socks. For example, such features and applications could be applied to and/or incorporated into gloves, mittens, stocking caps, sweaters, balaclavas, shirts, pants, various undergarments and foundation garments, pet and animal garments, etc.

BRIEF DESCRIPTION OF THE DRAWINGS

FIG. 1 is a right side elevational view of an example implementation of an expandable stretch sock of the present disclosure that can accommodate wearers of shoe sizes 10-13, sock sizes 7-9, and NAHM sizes 7-9 (shown in association with a conventional size 7 sock on a display device and a conventional size 9 sock on a display device);

FIG. 2 is a right side elevational view of an example implementation of an expandable stretch sock of the present disclosure that can accommodate wearers of shoe sizes 4-10, sock sizes 5-7, and NAHM sizes 5-7 (shown in association with a conventional size 5 sock on a display device and a conventional size 7 sock on a display device); and

FIG. 3 is a right side elevational view of an example implementation of an expandable stretch sock of the present disclosure that can accommodate wearers of shoe sizes 000-4, sock sizes 3-5, and NAHM sizes 3-5 (shown in association with a conventional size 3sock on a display device and a conventional size 5 sock on a display device).

DETAILED DESCRIPTION

As used in this document, the singular forms “a,” “an,” and “the” include plural references unless the context clearly dictates otherwise. Unless defined otherwise, all technical and scientific terms used herein have the same meanings as commonly understood by one of ordinary skill in the art. As used in this document, the term “comprising” means “including, but not limited to.” When used in this document, the term “exemplary” is intended to mean “by way of example” and is not intended to indicate that a particular exemplary item is preferred or required.

In this document, when terms such “first” and “second” are used to modify a noun, such use is simply intended to distinguish one item from another, and is not intended to require a sequential order unless specifically stated. The term “approximately,” when used in connection with a numeric value, is intended to include values that are close to, but not exactly, the number. For example, in some implementations, the term “approximately” may include values that are within +/−10 percent of the value.

When used in this document, terms such as “top” and “bottom,” “above” and “below”, “upper” and “lower”, or “front” and “rear,” are not intended to have absolute orientations but are instead intended to describe relative positions of various components with respect to each other. For example, a first component may be an “upper” component and a second component may be a “lower” component when a device of which the components are a part is oriented in a first direction. The relative orientations of the components may be reversed, or the components may be on the same plane, if the orientation of the structure that contains the components is changed. The claims are intended to include all orientations of a device containing such components.

FIGS. 1-3 present views of example implementations of expandable stretch socks to be worn on the foot of a wearer, generally 100, in accordance with the present disclosure. Socks 100 each include a generally tubular-shaped body portion 102 including a foot bed 104 configured to expand at least two sizes on the NAHM sock size measuring system. Socks 100 also include a toe portion 106, heel portion 108, and ankle/calf portion 110.

In example implementations shown in the figures, the body portion 102 and foot bed 104 of socks 100 are knit substantially entirely on the same needle cylinder/group (not shown) using the knitting technique of mesh knitting. This results in the sock 100 having a foot bed 104 with a broader range of fit for both foot length and width than is typical for sock manufacturing.

The body portion 102 and foot bed 104 are mesh knit substantially entirely on the same needle cylinder using heavier body yarns, lighter denier nylon fibers and/or stronger spandex fibers than is typical for manufacturing socks. By way of non-limiting examples, and as shown in FIG. 1, socks 100 can be produced pursuant to the present disclosure, where a pair of socks or single sock 100 a, shown in association with a conventional size 9 sock on a display device 112 a and a conventional size 7 sock on a display device 112 b, can accommodate wearers of shoe sizes 10-13, sock sizes 7-9, and NAHM sizes 7-9. Similarly, as shown in FIG. 2, another example single sock 100 b, shown in association with a conventional size 7 sock on a display device 114 a and a conventional size 5 sock on a display device 114 b , can accommodate wearers of shoe sizes 4-10, sock sizes 5-7, and NAHM sizes 5-7. Additionally, in a further example, as shown in FIG. 3, a single sock 100 c, shown in association with a conventional size 5 sock on a display device 116 a and a conventional size 3 sock on a display device 116 b, can accommodate wearers of shoe sizes 000-4, sock sizes 3-5, and NAHM sizes 3-5.

In other example implementations of the present disclosure, methods for manufacturing socks include selecting heavier body yarns, lighter denier nylon fibers and/or stronger spandex fibers than is typical for manufacturing socks and mesh-knitting a body portion and a foot bed to produce the sock 100, where the body portion 102 and foot bed 104 are configured to expand at least two sizes on the NAHM sock size measuring system while comfortably accommodating the foot of the wearer. The method can also include mesh knitting all, or substantially all, of the body portion 104 and the foot bed 104 on the same needle cylinder

As can be seen from the foregoing, the present disclosure relates to a sock having an expandable foot bed capable of fitting wearers in an increased range of sizes by virtue of selected fiber and/or knitting techniques. Also per the present disclosure, methods are provided for production of a sock knitted substantially entirely on the same needle group/cylinder in order to achieve a sock configured to handle an increased range of foot shapes and sizes. Further, the present disclosure provides methods using body yarns of heavier weight than is typical for sock manufacture and also yarns of lighter denier nylon and/or stronger spandex fibers than is typical for sock manufacture to control the sizing (combined with a preselected mesh knitting technique), to produce a sock with foot bed having a broader range of fit for both foot length and width.

In particular, a sock of the present disclosure is configured to expand up to two sizes on the NAHM sock size measuring system, thereby allowing such sock to accommodate multiple foot shapes and sizes while still allowing for a comfortable fit capable of providing the consumer with a customized feel. More specifically, in certain non-limiting examples, socks in accordance with the disclosure herein accommodated multiple size ranges, such as: in one example embodiment, a sock accommodates wearers of shoe sizes 10-13, sock sizes 7-9, and NAHM sizes 7-9; in a second example embodiment, a sock accommodates wearers of shoe sizes 4-10, sock sizes 5-7, and NAHM sizes 5-7; and in a third example embodiment, a sock accommodates wearers of shoe sizes 000-4, sock sizes 3-5, and NAHM sizes 3-5.

In one non-limiting example of the present disclosure, the body portion 102 and foot bed 104 are mesh knit substantially entirely on the same needle cylinder using heavier body yarns (for example, comprised of approximately 140-400 Denier fibers), lighter denier nylon yarns (for example, comprised of approximately 65-75 Denier fibers) and/or stronger spandex fibers yarns (for example, comprised of approximately 20-40 Denier fibers) than is typical for manufacturing socks.

Also, in non-limiting examples of the present disclosure, a 168 needle was used, and: a “large” sock 100 a was produced with 70 Denier plaiting and a body portion 102 with 24/1 cotton count (221 Denier); a “medium” sock 100 b was produced with 70 Denier plaiting and a body portion 102 with 30/1 cotton count (177 Denier); and a “small” sock 100 c was produced with 70 Denier plaiting and a body portion 102 with 36/1 cotton count (147 Denier).

Additionally, in non-limiting examples of the present disclosure, a 108 needle was used, and: a “large” sock 100 a was produced with 70 Denier plaiting and a body portion 102 with 14/1 cotton count (379 Denier); a “medium” sock 100 b was produced with 70 Denier plaiting and a body portion 102 with 16/1 cotton count (332 Denier); and a “small” sock 100 c was produced with 70 Denier plaiting and a body portion 102 with 20/1 cotton count (265 Denier).

The above-disclosed features and functions, as well as alternatives, may be combined into many other different apparatuses or applications. Various presently unforeseen or unanticipated alternatives, modifications, variations or improvements may be made by those skilled in the art, each of which is also intended to be encompassed by the disclosed implementations. 

1. A sock to be worn on the foot of a wearer, comprising a body portion configured, the body portion including a foot bed configured to expand at least two sizes on the National Association of Hosiery Manufacturers (NAHM) sock size measuring system while comfortably accommodating the foot of the wearer.
 2. The sock of claim 1, wherein the body portion and the foot bed are knit substantially entirely on the same needle cylinder.
 3. The sock of claim 1, wherein the body portion and the foot bed are knit substantially entirely by mesh knitting to produce the sock with the foot bed having a broader range of fit than is typical for sock manufacture for both foot length and width.
 4. The sock of claim 1, wherein the body portion and the foot bed are knit using body yarns of approximately 140 to 400 Denier fibers.
 5. The sock of claim 1, wherein the body portion and the foot bed are knit using yarns of denier nylon fibers of approximately 65 to 75 Denier.
 6. The sock of claim 1, wherein the body portion and the foot bed are knit using yarns of spandex fibers of approximately 20 to 40 Denier.
 7. The sock of claim 1, wherein the sock comfortably accommodates wearers of shoe sizes 10-13, sock sizes 7-9, and NAHM sizes 7-9.
 8. The sock of claim 1, wherein the sock comfortably accommodates wearers of shoe sizes 4-10, sock sizes 5-7, and NAHM sizes 5-7.
 9. The sock of claim 1, wherein the sock comfortably accommodates wearers of shoe sizes 000-4, sock sizes 3-5, and NAHM sizes 3-5.
 10. The sock of claim 1, wherein the body portion and foot bed are knit substantially using at least one of a group consisting of: body yarns of heavier weight than is typical for manufacturing socks; lighter denier nylon fibers than is typical for manufacturing socks; and stronger spandex fibers than is typical for manufacturing socks.
 11. The sock of claim 1, wherein the body portion and the foot bed are mesh knit substantially entirely on the same needle cylinder.
 12. The sock of claim 1, wherein: the body portion and foot bed are mesh knit substantially entirely on the same needle cylinder; and the body portion and the foot bed are knit using at least one of a group consisting of: body yarns of heavier weight than is typical for manufacturing socks; lighter denier nylon fibers than is typical for manufacturing socks; and stronger spandex fibers than is typical for manufacturing socks.
 13. The sock of claim 1, wherein the sock comfortably accommodates at least one of a group consisting of: shoe sizes 10-13, sock sizes 7-9, and NAHM sizes 7-9; shoe sizes 4-10, sock sizes 5-7, and NAHM sizes 5-7; and shoe sizes 000-4, sock sizes 3-5, and NAHM sizes 3-5.
 14. The sock of claim 1, wherein: the body portion and the foot bed are mesh knit substantially entirely on the same needle cylinder; and the sock comfortably accommodates at least one of a group consisting of: shoe sizes 10-13, sock sizes 7-9, and NAHM sizes 7-9; shoe sizes 4-10, sock sizes 5-7, and NAHM sizes 5-7; and shoe sizes 000-4, sock sizes 3-5, and NAHM sizes 3-5.
 15. The sock of claim 1, wherein: the body portion and the foot bed are mesh knit substantially entirely on the same needle cylinder; and the body portion and foot bed are knit using at least one of a group consisting of: body yarns of heavier weight than is typical for manufacturing socks; lighter denier nylon fibers than is typical for manufacturing socks; and stronger spandex fibers than is typical for manufacturing socks.
 16. A method for manufacturing a sock to be worn on the foot of a wearer, comprising: selecting at least one of a group consisting of: body yarns of heavier weight than is typical for manufacturing socks; lighter denier nylon fibers than is typical for manufacturing socks; and stronger spandex fibers than is typical for manufacturing socks; and mesh knitting a body portion and a foot bed to produce the sock, wherein the body portion and the foot bed are configured to expand at least two sizes on the National Association of Hosiery Manufacturers (NAHM) sock size measuring system while comfortably accommodating the foot of the wearer.
 17. The method of claim 16, wherein the mesh knitting of the body portion and the foot bed is substantially entirely performed on the same needle cylinder.
 18. The method of claim 16, wherein the selection step includes: selection of body yarns of heavier weight than is typical for manufacturing socks; selection of lighter denier nylon fibers than is typical than is typical for manufacturing socks; and selection of stronger spandex fibers than is typical for manufacturing socks.
 19. The method of claim 16, wherein: the mesh knitting of the body portion and the foot bed is substantially entirely performed on the same needle cylinder; and the selection step includes: selection of body yarns of heavier weight than is typical for manufacturing socks; selection of lighter denier nylon fibers than is typical than is typical for manufacturing socks; and selection of stronger spandex fibers than is typical for manufacturing socks.
 20. A sock to be worn on the foot of a wearer, comprising: a body portion configured, the body portion including a foot bed configured to expand at least two sizes on the National Association of Hosiery Manufacturers (NAHM) sock size measuring system while comfortably accommodating the foot of the wearer; wherein the body portion and the foot bed are knit substantially entirely on the same needle cylinder; wherein the body portion and the foot bed are knit using: body yarns of heavier weight than is typical for manufacturing socks; lighter denier nylon fibers than is typical than is typical for manufacturing socks; and stronger spandex fibers than is typical for manufacturing socks; and wherein the sock accommodates at least one of a group consisting of: shoe sizes 10-13, sock sizes 7-9, and NAHM sizes 7-9; shoe sizes 4-10, sock sizes 5-7, and NAHM sizes 5-7; and shoe sizes 000-4, sock sizes 3-5, and NAHM sizes 3-5. 